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AnsweredHot!robk's MR2 Turbo

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robk
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Re: robk's MR2 Turbo 2018/02/28 12:01:11 (permalink)
+1 (1)
The following parts have just been ordered from the US:
 
ATS Racing custom-ordered Wiseco 5S pistons (87.5mm, ~9:1 CR)
Pauter 5S Rods
ARP main studs
ARP rod bolts and head studs ('625+' upgrade, ie. the strongest available)
Hux Racing head stud support washers/hats
Hux Racing billet steel main caps
King race main bearings and rod bearings
ATS Racing 5SGTE MLS head gasket
New genuine water pump
New genuine high-flow oil pump
New genuine timing belt
Low-temp high-flow thermostat
5S flywheel bolts
5S rear main seal
Moroso oil pan
post edited by robk - 2018/06/22 23:23:40

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There is an extensive build thread for my car here: http://www.mr2australia.com/mr2play/tm.aspx?m=18316
Mrskylighter
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Re: robk's MR2 Turbo 2018/02/28 15:43:30 (permalink)
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That'll be a tough motor Rob :) I'm not up to speed on what that combo can handle. 800+WHP?
 
Are you staying with the current turbo with the 10% greater displacement (faster spool) or moving up a size?

1989 AW11 Gen3 3sgte
robk
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Re: robk's MR2 Turbo 2018/02/28 15:57:16 (permalink)
+1 (1)
This combination of parts is virtually the strongest you can get. 
I'm probably going to stay with the GTX3076R turbo and enjoy the improved spool, but with these parts the engine will support more power than I could ever want if I changed the turbo in the future (even if that never happens, it will be reassuring to know that I have a higher factor of safety than before). 
After looking at this https://www.perrin.com/blog/post/garrett-gtx-turbo-comparo-part-2 the GTX3582R becomes very tempting because it would have identical spool (thanks to 2.2L vs 2.0L) while allowing 500+rwkw, but I think I'd rather have better spool than what I have now. Also, it's easy to forget that the stock e153 gearbox may not be able to handle significantly more than 400rwkw.
post edited by robk - 2018/06/04 14:49:30

President of the MR2 Club of NSW. 
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robk
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Re: robk's MR2 Turbo 2018/04/27 12:03:35 (permalink)
+3 (3)
I miss my car!
It's now been 8 weeks, and ATS in the US are still waiting for the pistons to arrive so they can ship everything over.
 
I've been talking to Advance in the mean time, and it's likely that I'm going to proceed with twin in-tank staged fuel pumps, so I can have a good safety buffer rather than using up all of the available flow with my power level on a single Walbro E85 pump.
I'd like to upgrade the fuel return line to at least -6AN braided teflon hose (instead of the small stock return hard line on top of the tank), which will require the tank to come out anyway...hopefully for the final time!
 
I came up with my own custom strategy for controlling both fuel pumps, and I implemented it in my ECU last night in preparation. Here's how it will work:
- Each fuel pump will have its own relay controlled by separate ECU outputs
- Only 1 of the 2 pumps will run most of the time, until the flow of both pumps is required
- Every 5 minutes, the ECU will swap to the opposite fuel pump (but it will only do this in the over-run fuel-cut condition, so I won't feel it at all)
- By alternating the pumps periodically during cruise conditions or idle, I'm more likely to know if either of the pumps has a problem before the next time I intend to use all of the engine's power, in which case both pumps will need to be working correctly to achieve the expected fuel delivery
- Rather than having only a boost threshold setting for turning on both pumps, I thought it would be more ideal to turn on both fuel pumps based on the actual injector fuel-flow requirement exceeding a configurable value (my ECU already knows the litres per hour of fuel required by the injectors at any time, so it makes sense to utilise this information instead of just the boost level)

President of the MR2 Club of NSW. 
There is an extensive build thread for my car here: http://www.mr2australia.com/mr2play/tm.aspx?m=18316
Falcon
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Re: robk's MR2 Turbo 2018/04/30 07:29:46 (permalink)
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Some really nice bits you have ordered. Will twin pumps and their intake filters all actually fit through the hole into the tank?  Enlarging that pissy little steel return fuel line is definitely a good idea.  Have you considered access to fuel pump aperture via cabin at this time? A strategically positioned hole very carefully cut in the tunnel with a shaped plate secured by at least six bolts to spread the loads. We have no way to know what loads are involved in that tunnel area so it would need to be done properly.
Do you already have a gauge to monitor fuel pressure?
robk
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Re: robk's MR2 Turbo 2018/04/30 09:32:27 (permalink)
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Falcon
Will twin pumps and their intake filters all actually fit through the hole into the tank?

Unfortunately not if they're both Walbro F90000267 E85 pumps. There may be some other brands of pump that will fit into the hole alongside each other, but I'd prefer to use the Walbros because I know I can trust them. I'm expecting to have to enlarge the hole in the tank, maybe weld a different mounting boss onto it, then have a custom cover for the bigger hole.
 
Falcon
Have you considered access to fuel pump aperture via cabin at this time? A strategically positioned hole very carefully cut in the tunnel with a shaped plate secured by at least six bolts to spread the loads. We have no way to know what loads are involved in that tunnel area so it would need to be done properly.

The thought had crossed my mind, and other people have done it, but the tank has to come out this time regardless, and I hope this is the last time I'll ever have to change anything with it.
 
Falcon
Do you already have a gauge to monitor fuel pressure?

*EDIT* I have a fuel pressure sensor connected to the ECU.
post edited by robk - 2018/05/02 16:53:14

President of the MR2 Club of NSW. 
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robk
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Re: robk's MR2 Turbo 2018/05/07 09:11:13 (permalink)
+1 (1)
After 9 long weeks, I finally got a call this morning saying that the parts are going to be shipped from the US today!

President of the MR2 Club of NSW. 
There is an extensive build thread for my car here: http://www.mr2australia.com/mr2play/tm.aspx?m=18316
robk
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Re: robk's MR2 Turbo 2018/05/17 20:20:49 (permalink)
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The parts just turned up at Advance Motor Mechanics.
Here are photos of just some of the parts. 
*EDIT* I just dropped by and took some more/better photos myself. 

Pauter rods:

 

 

 


Wiseco forged pistons (ATS Racing did a custom order so the pistons could have ~9:1 CR):

 

 

 


Moroso oil sump:

 

 

 

 

 


Hux Racing billet main caps, and a few of the Hux Racing 'head stud support washers/hats' at the top:


ATS Racing MLS head gasket for 98+ 5SFE block with gen 2 3SGTE head:


I also got a photo of the top of the 98+ 5SFE block that we sourced, in case anyone is interested (at the bottom left corner of the block in the photo, where the edge of the block goes straight across, that's the spot where there was less metal on the earlier blocks, AFAIK):


Now the relevant items can be sent to the machinist/s. This might take a while too, but at least in the mean time we can get the twin in-tank fuel pump setup done. 

President of the MR2 Club of NSW. 
There is an extensive build thread for my car here: http://www.mr2australia.com/mr2play/tm.aspx?m=18316
Falcon
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Re: robk's MR2 Turbo 2018/05/18 06:58:13 (permalink)
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Wow. All that stuff looks the goods. The pistons have a nice long skirt to take thrust loads. A lot of stroker types are way too short in order to clear the rod. Very robust design.
Pauter rods also look tough. Very nice. Do they have an oil passage drilling from bigend to gudgeon or just the two oil holes near top to splash feed the gudgeon pin bushing ? Will this 5S. have oil squirters ?
And that sump!!  Will need a couple of mirrors to show it off to all us jealous buggers.
This really should be the ducks nuts of builds. Wish you well and thanks for the old proven bits you passed across to me. I like them too.
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Re: robk's MR2 Turbo 2018/05/18 07:13:32 (permalink)
+1 (1)
Exciting! It will be great to see another 5S on the track.

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Re: robk's MR2 Turbo 2018/05/18 09:27:16 (permalink)
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Looking good Rob. What solution are you going with for the oil level sensor hole in the Moroso pan? Something like the below?
 
https://primedriven.com/p...sensor-block-off-3sgte

1989 AW11 Gen3 3sgte
robk
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Re: robk's MR2 Turbo 2018/05/18 09:29:06 (permalink)
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Falcon
Wow. All that stuff looks the goods. The pistons have a nice long skirt to take thrust loads. A lot of stroker types are way too short in order to clear the rod. Very robust design.
Pauter rods also look tough. Very nice. Do they have an oil passage drilling from bigend to gudgeon or just the two oil holes near top to splash feed the gudgeon pin bushing ? Will this 5S. have oil squirters ?
And that sump!!  Will need a couple of mirrors to show it off to all us jealous buggers.
This really should be the ducks nuts of builds. Wish you well and thanks for the old proven bits you passed across to me. I like them too.

 
Thanks Doug.
 
It's interesting how different the Wiseco pistons are compared to my old CP pistons that are now yours.
 
I'm not sure about the answer to your question about the rods. I was so intrigued by the different cross-sectional shape of the Pauter rods compared to Eagle rods, I forgot to pay attention to the oil passages.
 
I won't have oil squirters.
 
The sump is beautiful isn't it! Now I won't have to stress about oil starvation due to cornering loads when I try r-comp semi-slicks for the first time in October (assuming that the car will be ready in time).

President of the MR2 Club of NSW. 
There is an extensive build thread for my car here: http://www.mr2australia.com/mr2play/tm.aspx?m=18316
robk
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Re: robk's MR2 Turbo 2018/05/18 09:32:48 (permalink)
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Mrskylighter
Looking good Rob. What solution are you going with for the oil level sensor hole in the Moroso pan? Something like the below?
https://primedriven.com/p...sensor-block-off-3sgte

I forgot about it until the sump arrived. I would've ordered that block-off plate with everything else if I had realised.
I'm going to need an AN fitting welded onto the sump in a similar location for my oil catch can return anyway, so I may just get an alloy plate welded over the oil level sensor hole while I'm at it.

President of the MR2 Club of NSW. 
There is an extensive build thread for my car here: http://www.mr2australia.com/mr2play/tm.aspx?m=18316
7hegame
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Re: robk's MR2 Turbo 2018/05/25 22:49:23 (permalink)
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Hi Rob
 
I'm new to these forums. I think I may have seen your SW20 on the hoist last week at Advance. I'll be bringing my SW20 (in black as well) over the next couple of weeks to get a turbo manifold and dump pipe made up. I just finished getting my 3sGTE rev2 built and GT3082 turbo rebuilt.
 
I'll try to drop by this Sunday at Silverwater, I have a christening just before.
 
Gary

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robk
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Re: robk's MR2 Turbo 2018/05/25 23:02:08 (permalink)
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Hey Gary, yeah that would've been my car at Advance!
Hopefully you'll be able to make it on Sunday.

President of the MR2 Club of NSW. 
There is an extensive build thread for my car here: http://www.mr2australia.com/mr2play/tm.aspx?m=18316
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